/stationary_machines_eng_2012

stationary machines shredding

screening

preparation

separation

komptech gmbh Komptech is a leading international technology supplier of machinery and systems for the mechanical and mechanical-biological treatment of solid waste and for the treatment of biomass as a renewable energy source.

The product range includes over 30 different types of machines, that cover all key process steps in modern waste handling - shredding, separation, and biological treatment.

By combining the right products from our own portfolio with proven components by other leading manufacturers, we can deliver solutions to address complex challenges.

The focus is always on innovative technology and solutions that ensure the maximum customer benefit.

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Contents shredding Terminator

terminator .................................................................................................... 4/5 Single-shaft shredder for pre-shredding crambo ............................................................................................................ 6/7 Dual-shaft shredder for wood and green waste rasor ................................................................................................................ 8/9 Post-shredder

Drum screen

screening multistar ..................................................................................................... 10/11 Star screen Drum screens ............................................................................................ 12/13 multistar

flowerdisc ...................................................................................................... 14 Disc separator preparation mashmaster .................................................................................................... 15 Universal mixer

Hurrikan

separation Screw press ..................................................................................................... 16 hurrikan .......................................................................................................... 17 Windsifter Ballistor

ballistor ..................................................................................................... 18/19 Ballistic separator 03

terminator

Single-shaft shredder for pre-shredding The Terminator is a slow speed, high torque single-shaft shredder for hard-to-shred waste. C&D, railroad ties, carpet, MSW and tires are no problem for the rugged teeth mounted on the shredding rotor and opposing counter comb. The stepless cutting gap allows adjustment of the size of the output material.

There is a choice of two drive systems – either a hydraulic system with optional disconnection from the shredding unit for constant power, or mechanical direct-drive for maximum efficiency.

Shredding of the most difficult materials Rugged design as pre-shredder provides high degree of shredding Variable particle size by adjusting cutting gap Hydraulic drive with constant power control and optional separated design or direct-drive with optimum degree of efficiency

04

specifications 500

2200

3400

3400S

5000

5000S

Details

6000S

Drive Hydraulic rating (kW): Mechanical rating (kW):

-

1 x 132

1 x 160

1 x 160

1 x 200

1 x 200

2 x 160

1 x 37

1 x 132

1 x 160

2 x 75

-

2 x 110

2 x 160

Shredding unit Length (mm):

3000

Drum diameter (mm):

1050

Drum rpm: hydraulic:

-

max. 29

max. 29

max. 27

max. 29

max. 29

max. 38

Drum rpm: mechanical:

3

17/13

19/14

14/10

-

20/14

28/20

~ 15.1

~ 15.5

~ 16.5

~ 15.8

~ 16.8

only separated unit

~ 13.6

~ 14.0

~ 15.0

-

~ 15.3

~ 15.8

-

up to 30

up to 45

up to 50

up to 60

up to 80

up to 100

up to 6

up to 20

up to 30

up to 35

-

up to 55

up to 75

Weight Hydraulic: (assembled unit) Mechanical:

~ 11.8

Throughput (dependent on material) Hydraulic (t/h): Mechanical (t/h):

shredding: Applications of the drum/ counter comb system range from coarse pre-crushing to defined shredding. The continuous cutting gap adjustment allows adjustment of the particle size for the intended use.

Hydraulic drive: Besides the standard stationary frame, separation of the drive unit from the shredding unit is provided as an option. The advantages: Better protection of drive unit (less dust, better cooling) and space-saving integration of the shredding unit into the process cycle.

Mechanical drive: The cost-effective mechanical drive offers low energy costs due to high efficiency.

The installation into the plant chain is simple: Set up connect - power on. Further features are two speeds for adaption to material and automatic reverse control.

Showcase Machine type: TM 5000 S Application: Commercial waste Throughput: 50 t/h

materials

Household waste

Bulky waste

Commercial waste

Waste wood

The highly variable content of commercial waste can require extreme shredding power – which is exactly what you get from the Terminator S version, with its dual drum drive.

The hydraulic drive provides the highest shredding power and prevents jamming and blockages. Clearing by reversing is possible at all times.

Tires

05

crambo

Dual-shaft shredder for wood and green waste The Crambo dual-shaft shredder shreds all types of wood and green waste, as well as pre-treated synthetic fractions, to a set particle size. Slow-running screws with shredding tools minimize fine particle and noise/dust emissions, and build up resistance to contamination.

The particle size is adjustable by simply exchanging screen baskets. A hydraulic drive with load-dependent speed control ensures maximum utilization of motor output.

Optional disconnection of the shredding unit from the drive simplifies integration into the system.

High throughputs with general-purpose use ggressive feed with 2820 mm long, counter-rotating A shredding drums Variable particle size with less overlengths and low fine fraction Quick-change system for screen basket and tools – screen basket change in minutes

06

specifications 3400

5000

6000

1 x 160

1 x 200

2 x 160

max. 32

max. 40

Details

Drive Power (kW): Shredding unit Number of screws: Drum rpm:

2 max. 31

Drum length (mm):

2820

Drum diameter (mm):

610

Cutting elements:

134

Weight (t) assembled unit

~ 16.0

~ 16.8

only separated unit

up to 45

up to 60

up to 100

Throughput Throughput performance (t/h): (dependent on material)

Shredding: Low-speed drums with shredding teeth minimize fine particle and noise/ dust emissions and resist contraries. The particle size is configurable by simply exchanging screen baskets.

Drive: With load-dependent speed regulation, the hydraulic drum drive ensures that full advantage is taken of the engine output. Besides the standard stationary frame, separation of the drive unit from the shredding unit is provided as an option

Application: The shredding concept provides a wide range of possibilities. Established applications are the shredding of bio-waste for composting, the shredding of market waste and food/ kitchen waste for a anaerobic digestion or the preshreddding of roof shingles.

Showcase Machine typ: Crambo 5000 Application: Waste wood Throughput: 50 t/h

materials

Waste wood

Green waste

Root stocks

When shredding waste wood, the wear-resistant teeth in combination with the hydraulic drive provide a high level of resistance to contraries.

Counter-rotating shafts, together with the special shape of the teeth, produce a perfect feed, even for fractions with high board content.

Forestry waste

07

rasor Post-shredder

The Rasor is a post-shredder for the generation of refuse derived fuels from pre-treated waste fractions.

The continuous material feed with screws ensures uniform power consumption.

The material is shredded (practically dust-free) by slowrunning cutters in the enclosed shredding unit. A simple cutting gap adjustment guarantees minimum energy expenditure during the shredding process. Best accessibility to the counter-cutter, the wearing parts and screen basket ensure short servicing times.

Continuous material feed with simple cutting gap adjustment for uniformly low power consumption Shredding with low levels of dust and noise Swivelling counter-cutter carrier provides optimal service accessibility Replacement of wearing parts with minimal servicing times

08

specifications

Details

5400 Drive Power (kW):

250

Material feed Type: Number of screws:

electric 3 x 7.5 kW 3

Cutter/rotor Length (mm):

1320

Diameter (mm):

1000

Rpm: Cutters: Screen basket hole size (mm):

149 3 x 18 25, 30, 40, 60

Dimensions L x W x H (mm): Weight (t):

4007 x 2689 x 2570 ~ 16

Throughput (dependent on material) Throughput performance (t/h):

Feeding: Three feed screws transport the material into the shredding area. Material is pressed continuously against the shredding rotor This guarantees consistent power consumption. Dust emissions are prevented due to the enclosed shredding area.

Shredding: The “Endless� shear cut between the rotor cutters and the counter cutter saves power and reduces vibration and noise. The rotor runs at a moderate 149 rpm, with high throughput. Particle size is defined by the screen baskets around the rotor.

Maintenance: The Rasor offers good access to all maintenance areas.

The pivoting advance frame provides an ideal working position for all maintenance in the shredding area. An auxiliary crane is available for screen basket changing.

up to 15

Showcase Machine type: Rasor 5400 Application: Comercial waste, shredded Throughput: 5 t/h (Screen basket 30 mm)

materials

Commercial waste

Depending on the screen basket chosen, the fuel size can run from 60 mm diameter down to 30 mm premium blow-in RDF, or even smaller fuel for coal-fired power plants.

Continuous feed by the screws and the ideal cutter/ counter-cutter arrangement gives a high efficiency.

09

multistar star screen machines

Star screen technology from Komptech is regarded as one of the most effective separation methods for organic waste. Precise separation selectivity irrespective of material moisture and adjustment of the particle size at the press of a button are particular features of the Multistar star screen.

Stationary Multistar star screen systems leave no customer requirement unaddressed. With its modular design, screen decks, feed metering container, wind sifter and stone/ magnet separation are tailored perfectly to the job at hand, generating up to 4 fractions in one operation.

Separation into 3 fractions (4-SE: 4 fractions), wind sifting, Fe-separation in one compact machine High throughput with precise selectivity – even with moist materials Simple speed control at the screen deck to change particle size in seconds Flexibly tailored solutions for specialist customer applications

10

specifications Multistar 2-SE

Multistar 3_SE

12

40

Fine screen 5985 x 1000 / 6.0 or Coarse screen 5863 x 1000 / 5.9

Fine screen 5863 x 1200 / 7.0 and Coarse screen 3998 x 1200 / 4.8

-

20

8 ..... 20 10 ..... 25

8 ..... 20 Standard: 10 ..... 25

30 ..... 60 60 ..... 90 90 ..... 120

30 ..... 50 Standard: 60 ..... 90 90 ..... 120

up to 150

up to 400

Details

Drive Power (kW): Screen segments Length x width (mm) / area (m²):

Feed hopper Hopper volume (m³): Screen sections Fine (mm): Coarse (mm):

Throughput (dependent on material) Throughput performance (m³/h):

Drive: The core of the star screens consists of one or more screen decks, depending on the model. The electrical drive of the star shafts with electric motors and frequency converters gives quiet, efficient and economical operation.

Particle size: Particle size can be controlled by varying the rotation speed of the star shafts. In just seconds the particle size can be changed within the range provided by the star size. The different star dimensions and arrangements cover screening sections from 8-150 mm.

cleaning: On the Multistar screeners, the screen units are kept continuously clean by carbide, ceramic or specially coated cleaning elements, as appropriate for the specific application. This keeps wear to a minimum, for economical operation.

Showcase Machine type: Multistar 3-SE Application: Compost Throuhput: 180 m3/h

materials

Compost

Biomass

Bark, wood chips Waste wood shredded

Screening is always in season with an stationary star screen. High throughput and selectivity are retained, even with variations in moisture content and various rotting stages, because each star has a wear-resistant cleaning finger that clears the gap to the surrounding stars on each rotation.

Waste shredded

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drum screens 1845, 2055, 2255, 2278, 2290, 2590, 25120

With stationary drum screens, a corresponding screening machine is available for every system size. Directly driven heavy-duty supporting wheels (1845/2055: DRUMGRIPdrive) provide quiet drum operation and top efficiency with reduced energy consumption and noise emissions. Variable configuration of sub-structure, servicing accessibility, enclosure and drive simplify adaptation to on-site conditions.

Designed for continual operation: optimal screen drum operating characteristics with reliable cleaning Variable configuration for perfect adaptation to deployment and locality Options: » Screen segment drum with segment change without dismantling drum » Special drum with anti-dirt strips for screening of residual waste » Three-fraction screening by using different screen drum hole sizes » Special carrier drum with interchangeable screening segments

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specifications 1845

2055

2255

2278

2290

2590

Details

25120

Drive Power (kW):

15

18.5

2 x 9.2

2 x 11

2 x 11

4 x 7.5

4 x 9.2

electrical via DRUMGRIP

electrical via DRUMGRIP

electrically via direct drive

electrically via direct drive

electrically via direct drive

electrically via direct drive

electrically via direct drive

Diameter (mm) (exterior):

1800

2000

2200

2200

2200

2500

2500

Length (mm) (exterior):

4500

5500

5500

7800

9000

9000

12000

22.5

30

32

48

56.5

61.5

85

Length (without walkways, mm):

6250

7350

7500

9800

11100

11100

14100

Width (mm):

2300

2700

3100

3100

3100

3400

3400

Height (mm):

3250

3400

3600

3600

3600

4000

4000

up to 120

up to 160

up to 190

up to 250

up to 250

up to 275

up to 300

System:

Screening drum

Screening area (m²): Dimensions

Throughput (dependent on material) Throughput performance (mÂł/h):

Drive: The screen drum is driven by two to four direct drive units.

Power is transferred directly to the supporting wheels via a pinion slip on gear mechanism and then on to the screen drum via traction.

The positioning of the drive motors is freely selectable.

Screen drum: On stationary screen machines, drums up to 2.5 meters in diameter and up to 12 meters in length are used. A high throughput performance is guaranteed by feed screws welded on the inner side of the drum.

maintenance: A high degree of flexibility applies to the design of the gangways, steps etc. everything can be tailored to customer requirements.

Doors and a removeable tarpaulin cover allow comfortable access to the screen drum for cleaning.

Showcase Machine type: SM 2278 Application: Household waste Throughput: 180 t/h

materials

Compost

Biomass

Waste wood

Waste shredded

Ample space between screen drum and sidewalls also makes operation with large screen hole sizes go smoothly. For these hole sizes, outside scrapers are more effective than circular brushes for drum cleaning. For residual waste screening, a special drum with anti-dirt strips is also available.

Soil, Gravel, Sand

13

flowerdisc disc separator

The Flowerdisc represents a further technology for the screening of pre-shredded commercial, bulky and biowaste, a technology which combines high throughput, selectivity and resistance to contamination. Material is transported by shafts with rugged steel discs working on the disc screen principle. Movable jacketed pipes positioned between the discs prevent seizures and blockages by contraries.

Designed for separation of oversized particles from commercial waste, bulky waste, household waste and fresh bio-waste High throughput, low energy expenditure Sturdy design allows smooth, low-wear operation Modular design for flexible configuration in stationary systems

flowerdisc Drive Power dependent on configuration (kW):

17.5-22

Screen segments fine or coarse Length x Width (mm):

materials

FD 40: 5840 x 1200 FD 80: 6080 x 1200

Screen sections (standard) FD 40 (mm):

30 ..... 50

FD 80 (mm):

80 ..... 100

Throughput (dependent on material) Household waste

14

Commercial waste

Bio waste

Throughput performance (t/h):

up to 40

mashmaster universal screw mixer

Wet organic waste, woody structure material and various aggregates (residual waste and sewage sludge) are treated by the general-purpose Mashmaster mixing shredder into an output mixture ideal for the rotting process.

Four electrically driven screw shafts keep the material in an intensive mixing motion.

Rugged tools on the screws disentangle the material and provide shredding and homogenisation.

Shredding-mixing-homogenization in one machine Accurate definition of the mixing ratio, and automation with conveyor belt feed possible with electronic scales Prolonged service life with wear-resistant tools, tray with interchangeable base

mashmaster Drive Power (kW):

2 x 75 elektric

Container Volume (m続):

15

Mixing unit

materials

Assembly:

4 screws / mechanical drive

Dimensions L x W x H (mm): Weight (t):

6740 x 2200 x 2133 13.7

Throughput (dependent on material) Household waste

Bio waste

Green waste

Throughput performance (t/h):

up to 55

15

screw press The screw press can separate wet bio-waste into a solid fraction for composting and a liquid fraction for wet fermentation. Two screw shafts in the mixing container keep the material in an intensive mixing motion.

Crushing is performed by two press screws.

Other applications include drainage of organic material leachate during fermentation processe.

Mixing and crushing in one machine Different degrees of crushing attainable using various screen baskets Prolonged service life by using wear-resistant tools and tray with exchangeable base Corrosion-resistant steel used for all parts coming into contact with material (with exception of the press screw)

screw press Drive Power (kW):

1 x 132 kW electric

Mixing unit Container capacity (m3): Mixing equipment:

materials

15 2 screws / hydrostatic drive

Press Number of press screws: Length of press screws (mm): Compression ratio:

2 (Duplex) 4300 to 1 : 7

Throughput (dependent on material) Bio waste

16

Throughput performance (t/h):

12-20

hurrikan windsifter

The stationary Hurrikan high-performance windsifter allows effective cleaning of over-sized screened particles. The unit is extremely compact for a windsifter and can be integrated easily into a system chain. The patented „pressure-suction“ principle is used to separate plastic with a high degree of selectivity.

Outstanding windsifting using "pressure-suction" principle in conjunction with vibration At high throughput, in excess of 90% selectivity by precise adjustment of settings to material properties Simple integration into new or existing systems

hurrikan

hurrikan s

Drive Electric motor (kW):

28

47

Diesel generator (kVA):

53

60

up to 1200

up to 1200

7250 x 2000 x 4200

9800 x 2460 x 4000

~ 3.5

~ 6.0

up to 40

up to 60

Feed

materialien

Conveyor belt width (mm): Dimensions L x W x H (mm): Weight (t): Throughput (dependent on material) Compost

Biomass

Throughput performance (m3/h):

17

ballistor ballistic separator

The Ballistor is used to separate out usable fractions from waste and potential recyclables. By combining ballistic separation with screening, separation is performed in one operation in accordance with the criteria 3/2-dimensional, rolling-cubic-rigid/flat-soft-narrow, or undersized/oversized particles.

With a choice of separation into three or four fractions, five sizes and many options, the Ballistor separator can be configured to suit the application.

Wide range of applications – from municipal waste (household waste, commercial waste) to potential recyclables and building material waste High degree of selectivity with setting of separation limit Efficient drive design with low power requirement Rugged design with long service life and low operating costs

18

specifications 4300

4400

6300

6400

8300

8400

10300

10400

12300

12400

5.5

5.5

5.5

5.5

11.0

11.0

11.0

11.0

11.0

11.0

Number of fractions:

3

4

3

4

3

4

3

4

3

4

Number of screening elements:

4

4

6

6

8

8

10

10

12

12

5600

6800

5600

6800

5600

6800

5600

6800

5600

6800

9.6

11.6

14.4

17.4

19.2

23.3

23.9

29.1

28.7

34.9

Length (mm):

7475

8675

7475

8675

7475

8675

7475

8675

7475

8675

Width (mm):

2400

2400

3250

3250

4100

4100

4960

4960

5810

5810

Height without inlet cap (mm):

1930

1930

1930

1930

1930

1930

1930

1930

1930

1930

Transport width (mm): (pre-assembled unit)

2150

2150

3000

3000

3940

3940

4800

4800

5650

5650

~ 5.75

~ 6.5

~ 7.0

~ 7.75

~ 8.5

~ 9.25

~ 9.75

~ 10.5

~ 11.0

~ 11.75

up to 80

up to 100

up to 120

up to 130

up to 150

up to 160

up to 180

up to 200

up to 220

Details

Drive Power (kW): Screen elements

Length screening elements (mm): Screening area (m²): Dimensions

Weight (t):

Throughput (dependent on material) Throughput performance (mÂł/h):

up to 60

3D

Fine Fine fraction 1 fraction 2

2D

Separation physics: The 2-dimensional fraction is transported upwards. The 3-dimensional fraction is moved downwards by the ballistic movement, and removed. Variable hole sizes of the screen elements further sort the rising material to separate out the fine fraction.

Reliable: A new drive system using an electric motor, crankshaft, and elastic connecting link provides long service life.

Automatic lubrication options combined with electronic monitoring make the machine dependable even under heavy-duty operation.

Low operating costs: The low power requirements of the simple yet efficient mechanism keep energy costs low, they are at 4 - 8 kW. Three screen element designs and a choice of different materials lets the operator select the best configuration for the task, to reduce the wear and maintenance costs.

Showcase Machine type: 6400 Application: Commercial waste Throughput: 100 m3/h

materials

Commercial waste

Household waste

The rigid screen elements are arranged lengthwise and facilitate excellent turning of the material and hence a high degree of sorting. The separation threshold between the light and heavy fraction can be tailored to the material on site by adjustment of the infeed flap and the inclination.

Bulky waste

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Technology for a better environment

Komptech GmbH Kühau 37, A - 8130 Frohnleiten [t] +43 3126 505-0 [f] +43 3126 505-505 [e] info@komptech.com Komptech UK Ltd. Forge End, Lodge Farm Kineton Warwickshire, CV35 0JH [t] +44 1926 64 29 72 [f] +44 1926 64 29 71 [e] info.uk@komptech.com

www.komptech.com We reserve the right to make technical changes in the course of ongoing development. E2012